Gear transmission type range extender

Abstract

The utility model provides a gear transmission type range extender, and relates to the technical field of range extenders. The device comprises a front shell, a main shell and a rear shell, the front shell, the main shell and the rear shell are fixedly connected in sequence, a first cavity is formed between the front shell and the main shell, and a second cavity is formed between the main shell and the rear shell; an input shaft and a generator gear shaft are arranged in the first cavity in parallel, and a motor assembly is arranged in the second cavity; one end of the input shaft is connected with the generator gear shaft through the transmission gear set, the other end of the input shaft is connected with the engine, one end of the generator gear shaft is connected with the transmission gear set, and the other end of the generator gear shaft is connected with the motor assembly. The input shaft and the generator gear shaft are connected in a gear set transmission mode, it is guaranteed that the rotating speed of the generator is matched with the rotating speed of the engine when the engine operates in an efficient interval, transmission efficiency is improved, and energy consumption loss is reduced.

Description

Technical Field

[0001] The utility model relates to the technical field of range extenders, and specifically, the utility model relates to a gear transmission type range extender. Background Art

[0002] A range extender is an electric vehicle component that can provide additional electrical energy to increase the mileage of an electric vehicle. Simply put, a range extender is a combination of an engine and a motor. The range extender used in electric vehicles generally uses an internal combustion engine to drive a generator to charge the battery to increase the mileage. Compared with other new energy vehicles, the configuration system of extended-range electric vehicles is simple, and more importantly, the performance is more reliable and the cost is lower. Compared with electric vehicles, extended-range electric vehicles do not have to worry about the vehicle's cruising range, and can also reduce vehicle costs. At the same time, the range extender on the car can also be regarded as an additional energy storage component on a pure electric vehicle. During the driving process of the car, when the battery of the car is exhausted, other energy sources can be used to supplement the electricity.

[0003] With the development of new energy vehicles, people's requirements for electric vehicles are no longer just energy saving, but are beginning to shift towards power and driving experience, and extended-range electric vehicles have emerged. Extended-range electric vehicles have the advantages of long driving range, strong power, simple structure, and wide application.

[0004] However, the existing range extender often uses the method of directly connecting the engine and the generator to drive the generator to charge the battery. This structure cannot match the high efficiency range of the generator with the high efficiency range of the engine, and the energy consumption is high. Therefore, there is an urgent need for a new range extender that can match the high efficiency range of the engine with the high efficiency range of the generator, so as to solve the shortcomings of the existing technology and meet the user's demand for energy saving. Utility Model Content

[0005] In order to solve the technical problems existing in the prior art, the utility model provides a gear-driven range extender, which can match the high-efficiency range of the generator with the high-efficiency range of the engine by designing the input shaft and the generator gear shaft as a gear set transmission mode.

[0006] The utility model provides a gear transmission range extender, comprising a front housing, a main housing and a rear housing;

[0007] The front shell, the main shell and the rear shell are fixedly connected in sequence, a first cavity is formed between the front shell and the main shell, and a second cavity is formed between the main shell and the rear shell;

[0008] An input shaft and a generator gear shaft are arranged in parallel inside the first cavity, and a motor assembly is arranged inside the second cavity;

[0009] One end of the input shaft is connected to the generator gear shaft through a transmission gear set, and the other end of the input shaft is connected to the engine. One end of the generator gear shaft is connected to the transmission gear set, and the other end of the generator gear shaft is connected to the motor assembly. The transmission gear set has a preset transmission ratio.

[0010] Furthermore, the front housing is basin-shaped, with a recessed side for mounting the flywheel assembly and the other side connected to the main housing.

[0011] Furthermore, a water jacket is provided in the second cavity, and the water jacket is provided on the periphery of the motor assembly.

[0012] Furthermore, a water inlet is provided on the main shell, and the water inlet is connected to the water jacket.

[0013] Furthermore, the transmission gear set includes a first gear and a second gear, the first gear is meshed with the second gear, the first gear is connected to the output end of the engine, the second gear is connected to the input end of the motor assembly, and the first gear is larger than the second gear.

[0014] Furthermore, a rotary transformer is provided at the junction of the rear housing and the motor assembly.

[0015] Furthermore, a three-phase terminal block is installed on the rear housing.

[0016] Furthermore, a cold-pressed terminal is installed on the rear housing.

[0017] Furthermore, the first gear and the second gear are both helical gears.

[0018] Furthermore, one end of the generator gear shaft connected to the motor assembly is interference fit.

[0019] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0020] 1. The utility model connects the input shaft and the generator gear shaft by adopting a gear set transmission method, so that the high-efficiency range of the generator can be matched with the high-efficiency range of the engine, thereby reducing energy consumption.

[0021] 2. The utility model sets the front housing in a basin shape, so that the engine can be set in the depression, which saves the layout space of the powertrain and facilitates the subsequent vehicle development.

[0022] 3. The utility model can effectively prevent the generator gear shaft and the motor assembly from rotating relative to each other by designing one end where the generator gear shaft is connected to the motor assembly to be an interference fit. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Figure 1 It is a simplified schematic diagram of a preferred embodiment of the utility model.

[0024] In the figure: 1-input shaft, 2-generator gear shaft, 3-front housing, 4-main housing, 5-rear housing, 6-engine, 7-motor assembly, 8-water jacket, 9-rotating transformer, 10-three-wire connector, 11-cold pressure terminal, 12-controller, 13-spline, 14-water inlet, 20-transmission gear set, 21-first gear, 22-second gear. DETAILED DESCRIPTION

[0025] The technical solution of the utility model will be described clearly and completely below in conjunction with the accompanying drawings. Obviously, the described embodiments are part of the embodiments of the utility model, not all of the embodiments. Based on the embodiments of the utility model, all other embodiments obtained by those skilled in the art without creative work are within the scope of protection of the utility model.

[0026] In the description of the present invention, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", "clockwise", "counterclockwise" and the like indicating directions or positional relationships are based on the directions or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific direction, be constructed and operated in a specific direction, and therefore should not be understood as a limitation on the present invention.

[0027] In addition, the terms "first" and "second" are only used for descriptive purposes and cannot be understood as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Therefore, the features defined as "first" and "second" may explicitly or implicitly include one or more of the said features. In the description of the present utility model, "multiple" means two or more, unless otherwise clearly and specifically defined. In addition, the terms "installed", "connected", and "connected" should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection, or it can be indirectly connected through an intermediate medium, or it can be the internal connection of two components. For those skilled in the art, the specific meanings of the above terms in the present utility model can be understood according to specific circumstances.

[0028] As attached Figure 1As shown, the utility model provides a gear-driven range extender, in which the input shaft 1 and the generator gear shaft 2 are designed as a gear set transmission mode, and the transmission gear set 20 has a preset transmission ratio, so that the speed of the generator when the generator operates in the high-efficiency range matches the speed of the engine 6 when the engine operates in the high-efficiency range.

[0029] The gear transmission range extender comprises a front housing 3, a main housing 4 and a rear housing 5;

[0030] The front housing 3, the main housing 4 and the rear housing 5 are fixedly connected in sequence, the front housing 3 is assembled on one side of the main housing 4, and the rear housing 5 is assembled on the other side of the main housing 4, a first cavity is formed between the front housing 3 and the main housing 4, and a second cavity is formed between the main housing 4 and the rear housing 5;

[0031] An input shaft 1 and a generator gear shaft 2 are arranged in parallel inside the first cavity. One end of the input shaft 1 is connected to the engine 6 through a spline 13, and the other end is connected to the generator gear shaft 2 through a transmission gear set 20. The input shaft 1 receives torque from the engine 6 and drives the transmission gear set 20 to rotate. One end of the generator gear shaft 2 is connected to the transmission gear set 20, and the other end is connected to the motor assembly 7. The generator gear shaft 2 can rotate under the drive of the transmission gear set 20, convert mechanical energy into electrical energy, and transmit the electrical energy to the motor assembly 7. The motor assembly 7 is arranged in the second cavity;

[0032] When in use, the engine 6 starts working and converts heat energy into mechanical energy. The input shaft 1 receives the mechanical energy generated by the engine 6 and starts to rotate, driving the transmission gear set 20 meshing with the input shaft 1 to rotate. The transmission gear set 20 then drives the generator gear shaft 2 meshing with another part thereof to rotate, converting the mechanical energy into electrical energy, thereby supplying power to the motor assembly 7.

[0033] In a preferred embodiment of the present utility model, the front shell body 3 is basin-shaped, and the basin-shaped front shell body 3 does not have a recessed side connected to the main shell body 4. The side of the basin-shaped front shell body 3 that is not connected to the main shell body 4 forms a groove-shaped accommodating space, which can be used to accommodate the engine 6, and then the engine 6 is placed outside the range extender housing. While reducing the volume, it also has the advantages of easy maintenance, simple structure, and small space.

[0034] In a preferred embodiment of the utility model, a water jacket 8 is further provided in the second cavity. The water jacket 8 is arranged on the periphery of the motor assembly 7. The water jacket 8 is used for heat exchange and cooling of the motor assembly 7 to prevent the motor assembly 7 from generating a large amount of heat during charging and causing dangers such as explosion.

[0035] In a preferred embodiment of the utility model, a water inlet 14 is provided on the main shell 4, and the water inlet 14 is divided into a water inlet and a water outlet. One end of the water inlet is connected to the water jacket 8, and the other end is connected to the cooling device. The coolant can flow into the water jacket 8 from the cooling device through the water inlet, and flow out of the water jacket 8 from the water outlet after heat exchange and return to the cooling device. The cooling device is provided with a controller, and the motor assembly 7 is provided with a temperature sensor. The controller can control the coolant flow rate according to the temperature data of the motor assembly 7 monitored by the temperature sensor, thereby reducing consumption.

[0036] In a preferred embodiment of the utility model, the transmission gear set 20 includes a first gear 21 and a second gear 22, the first gear 21 and the second gear 22 are meshed, and there is no relative rotation between the first gear 21 and the second gear 22, the first gear is connected to the output end of the engine 6, the second gear is connected to the input end of the motor assembly 7, and the size of the first gear 21 is larger than the second gear 22. The gear ratio of the first gear 21 to the second gear 22 can be determined according to the ratio of the speed of the engine when it is in the high-efficiency speed range to the speed of the generator when it is in the high-efficiency speed range.

[0037] In a preferred embodiment of the present utility model, a rotary transformer 9 is provided at the junction of the rear housing 5 and the motor assembly 7. The rotary transformer 9 is used to measure the angular displacement and angular velocity of the motor, and then monitor the working state of the motor. It has the advantages of good shock resistance, high precision, fast conversion speed and insensitivity to mechanical and electromagnetic noise, and meets the application environment and use requirements of pure electric vehicles.

[0038] In a preferred embodiment of the utility model, a three-phase terminal 10 is installed on the rear housing, through which the controller can be quickly connected. Due to the quick plug and unplug, there is no need for repeated wiring, which can reduce maintenance costs.

[0039] In a preferred embodiment of the present invention, a cold-pressed terminal 11 is installed on the rear housing. The use of the cold-pressed terminal can reduce the loss of the electrical connection, improve the durability of the electrical connection, and reduce the maintenance cost.

[0040] In a preferred embodiment of the present invention, the first gear 21 and the second gear 22 are both helical gears. Compared with spur gears, helical gears have the advantages of good meshing, smooth transmission and low noise. At the same time, the overlap is large, which reduces the load on each pair of gears, improves the bearing capacity of the gears, and has a small minimum number of teeth to avoid root cutting.

[0041] In a preferred embodiment of the present invention, the tail end of the generator gear shaft 2 is interference fit with the motor assembly 7, which can prevent relative rotation between the generator gear shaft 2 and the motor assembly 7, thereby preventing the relative rotation from affecting the power transmission efficiency.

[0042] The above description is only a preferred embodiment of the utility model and is not intended to limit the utility model. For those skilled in the art, the utility model may have various modifications and changes. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the utility model are included in the protection scope of the utility model.

Claims

1. A gear transmission range extender, characterized in that: It includes a front shell, a main shell and a rear shell; The front shell, the main shell and the rear shell are fixedly connected in sequence, a first cavity is formed between the front shell and the main shell, and a second cavity is formed between the main shell and the rear shell; An input shaft and a generator gear shaft are arranged in parallel inside the first cavity, and a motor assembly is arranged inside the second cavity; One end of the input shaft is connected to the generator gear shaft through a transmission gear set, and the other end of the input shaft is connected to the engine. One end of the generator gear shaft is connected to the transmission gear set, and the other end of the generator gear shaft is connected to the motor assembly. The transmission gear set has a preset transmission ratio.

2. The gear transmission range extender according to claim 1, characterized in that: The front housing is in a basin shape, with a concave side for mounting the flywheel assembly and the other side connected to the main housing.

3. The gear transmission range extender according to claim 1, characterized in that: A water jacket is also provided in the second cavity, and the water jacket is provided on the periphery of the motor assembly.

4. The gear transmission range extender according to claim 3, characterized in that: The main shell is provided with a water inlet, and the water inlet is connected to the water jacket.

5. The gear transmission range extender according to claim 1, characterized in that: The transmission gear set includes a first gear and a second gear, the first gear is meshed with the second gear, the first gear is connected to the output end of the engine, the second gear is connected to the input end of the motor assembly, and the first gear is larger than the second gear.

6. The gear transmission range extender according to claim 5, characterized in that: The first gear and the second gear are both helical gears.

7. The gear transmission range extender according to claim 1, characterized in that: A rotary transformer is arranged at the junction of the rear housing and the motor assembly.

8. The gear transmission range extender according to claim 1, characterized in that: A three-phase terminal is installed on the rear housing.

9. The gear transmission range extender according to claim 1, characterized in that: The rear housing is provided with a cold-pressed terminal.

10. The gear transmission range extender according to claim 1, characterized in that: The generator gear shaft is interference fit with one end connected to the motor assembly.

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